Naphthyl condensed novolak



United States Patent O The condensation of a :novolalc resin with a '1chloro-1- phenols, oand p-isopropyl phenols, oand p-tert-ibutyl phenols, oand p-sec-ibutyl phenols, cand p-arnyl phenols, oand poctyl phenols, o and p-nonyl phenols etc, 2,5- xylenol, 3,4-xylenol, 2,5-diethyl phenol, 3,4-diethyl xylenol, 2,5-diisopropyl phenol, 4-methyl resorcinol, 4-ethyl resoncinol, 4-isopropyl resorci-nol 4-tert butyl resorcinol, etc., oand p-benzyl phenol, oand p-phenethyl phenols, This invention relates generally to nov-olak resins. d p-phze nyl h ol lond p-tolyl henols, 0- and Nowolak resins are widely used for moldings and cast 1 1 phenols, and pwycmhexyl phenols, and ings and ill the manufacture coatings, adhesives, and cyclopentyl phenols, etc, 4-phenet-hyl resorcinol, 4-tolylthe like. The resins are ponma-nently thermoplastic until i l, 4-i y lohexyl re or inol, et N 811611 time a y the cured, example, y hexamethyl- Any aldehyde may be used which will condense with ene tetraamine and the like. The novollak resins are h particular h l b i i S i bl gld h d [made y the condensation Phenol with an aldehyde include formaldehyde, acetaldehyde, propio-naldehyde, in an acid medium and are usually chains connected by b ld h hepbaldehyde, benzaldehyde furfuraldea methylene brl'd g hyde, glyoxal, etc, or compounds capable of engender- There has now been discovered, in accordance with this m aldehydes Such as pamionmaldehvde, hexamethylene invention, a novel resin of the-nwolak yp wherein tetraami-ne, etc. The .aldehydes can also be used in the p y group is included in the mehhyle'he The form of a solution, such as the commercially available novel resin is made by the condensation of a novolak f li re With ohl'oromethyl haphthalehe- The oondensafihh To :give dispersi'ble resins, greater than 0.5 mole or 50 is family cahried Out at elevated tempemhh'es in the mole percent-ofialdehyde provided per mole of phenol. presence or" a Friedel-Onafts catalyst such as zinc chloride. Th ti ll i d t h l t o ion 1 0 resinous products, at least about 67 mole percent of aldemeihylhaphfihalehe results in the p y twin-mating fi hyde should be combined with one mole of phenol. In resln'asl actual practice, however, it is necessary to use at least about 75-80 percent of aldehyde since some aldehyde is lost during the reaction, the amount lost depending on OH I" OH (1)11 OH CH2 GH: -CHr the conditions of the reaction. a For example, the use of 60 mole percent aldehyde usually gives only about mole percent combined aldehyde, thus giving a nonresinous product of the bis-phenol type. However, if excess is used so that 60 mole percent of the aldehyde M is combined with the phenol the product is a mixture of resin and bis-phenol compound. When amounts larger 3,290,271 NAPHTHYL CONDENSED NOVOLAK John OBrochta, Pittsburgh, Pa., assignor to Koppers Company, Inc., a corporation of Delaware No Drawing. Filed Apr. 1, 1963, Ser. No. 269,802 5 3 Claims. (Cl. 260-59) The condensation of the novolak resin with di-(w-ChiOIO- methyD-naphthalene intersperses the naphthyl :group in the methylene chain as t ...l 1.1 0H t l Om Oi J.

In both. cases, n=1 to 8. than about 67 mole percent up to a theoretical mole per- The n-ovolak resin for use in this invention may be precent of 100 are combined, higher molecular Weight polypared by any of the well-known procedures for carrying mers result. out phenol-aldehyde condensations. Ondinarily the 5 The novolak resin resulting from the foregoing comphenol and the aldehyde are condensed by reacting them prises a series of phenyl groups connected by methylene together in the presence of an acidic condensation catalyst bridges. Thus, when three moles of. para-cresol and two until the products have become relatively viscous. Solmoles of formaldehyde are combined the condensation vents may be employed. Elevated temperatures naturally product has a structure predominantly: accelerate the rate of reaction. 50 Advantageously, the nov-olak resin is prepared from phenols having only two aldehyde-reactive positions avail- OH 0H able for condensation with an aldehyde as this generally assures the thermoplastic nature of the resin sincethere OH is little possibility of cross-linking condensations which might cause premature thermosettinig.

Such phenols have the general formula: I

CH CH CH 0H With a ratio of six moles of par-acres-ol and =five moles A of combined formaldehyde, the product is predominantly:

Where OH OH OH 0H OH on A and B- may be hydrogen, an alkyl group or a hydroxyl OH gnoup R is a hydrooa-nbon group such as alkyl, aryl, aralkyl,

alka-ryl cycloalkyl, etc. O l I I I I CH3 CH3 CH3 CH3 CH3 CH3 Such phenols include oand p cresols, oand p-ethyl The chlorornet'hyl naphthalene may be 1-chloro-1- methylnapht-halene having the formula:

([lHaOl or -di-(w-chl-onomethyl)-naphthalene having the formula:

CHzOl j CHzCl EXAMPLE I N ovolak A one liter resin flask was charged with 324 grams o-cresol, 200 grams of 45% aqueous formaldehyde and 3 grams oxalic acid dihydrate. The mix was heated with stirring at such a rate that 90 minutes were required to attain refluxing conditions (98-101 C.). Refluxing was then continued for 2 hours. Thereafter, the Water and unreacted o-cresol were removed by distillation at atmospheric pressure to a temperature of 145 C. and then at 25 mm. mercury absolute to a final stripping temperature of 150 C. There was obtained 350 grams of a pale resin having a softening point of 99 C. (R. and B.).

1 -chlr0-1-methyl naphthalene A charge of 768 grams of pulverized naphthalene is mixed with 750 grams of an aqueous solution of formaldehyde (30 percent strength) and 3000 grams of concentrated hydrochloric acid. The mixture is heated to between 60 and 70 C, with agitation and hydrogen chloride is added. After hours, the oil floating on the surface of the reaction mixture is separated and distilled under reduced pressure to recover unreacted naphthalene, and l'-chloro-l methyl-naphthalene. The normally solid l-chloromethyl naphthalene boils at 153 C. under a pressure of 12 mm. mercury. It is purified by recrystallizing from alcohol.

N ovolak naphthalene resin A one liter flask was charged with 175 ml. monoc-hlorobenzene, 120 grams (0.2 In.) 99 o-cresol novolak 4. and 0.06 g. ZnCl and heated to C. Thereafter, 71 g. (0.4 m.) of monochlorornethyl naphthalene was then added at this temperature over a period of two hours. Strong and immediate evolution of HCl took place upon the addition of the 1'-chloro-1-methyl naphthalene. After chloromethyl naphthalene addition had been completed, the mix was stirred for six hours at C. and then cooled to 100 C. The reaction mass was filtered. Then the filtrate was distilled at a pressure of 7 mm. mercury and 200 C. oil bath temperature. There was thus obtained 172 g. of a light amber resin having a softening point of 133 C., a molecular weight of 838 and a hydroxyl content of 9.8%

EXAMPLE 11 To a flask equipped with a reflux condenser, a stirrer, and a thermometer was charged a mixture of 300 grams of an aqueous solution of formaldehyde (30% strength) and 200 grams of concentrated hydrochloric acid. Then, 90 grams of naphthalene was added. The mixture was heated to reflux and with stirring a current of gaseous hydrogen chloride was introduced for about 12 hours. After cooling, the reaction mass was separated from the mother liquor. The solid was filtered from the mother liquor, Washed with water, and dried under a vacuum. The crude product was purified by recrystallization from acetone to yield :a mixture of about equal parts of 1,4- and 1,5-di-(w-chloromethyl)-naphthalene isomers.

There was dissolved 120 grams (0.2 mole) of 99 C. softening point (R. & B.) ortho-cresol novolak (made as in Example I) having a molecular weight of 605 and a hydroxyl content of 14.1% in 200 milliliters of monochlorobenzene by the warming of the solvent. Then the solution was cooled to 30 C., and 22.5 (0.1 mole) of di-(w-chloromethyl)-naphthalene was added. Heat was applied and a complete solution resulted at about 60 C. As a catalyst, 0.04 gram of zinc chloride was added. The temperature of the solution was gradually raised; at about 100 C. evolution of hydrogen chloride commenced and refluxing started at about C. The hydrogen chloride solution had stopped after six hours of refluxing. The trace amounts of colloidal solids that appeared to be present were filtered out and the filtrate was vacuum distilled to a temperature of C. at 10 millimeters of mercury. The residue was a tan resin having a softening point of 152 C. (R. & B.), an average molecular weight of 1320 and 12% hydroxyl content.

The foregoing has described a novel novolak resin which has been modified by the addition thereto of large aromatic groups. The aromatic groups enhance aromatic character of the resin, -i.e., the resistance to the common solvents and to Water. The resin can be handled by conventional novolak procedures. For example, the resin can be cured with hexamethylene tetraamine. The cured resin has better thermal ablative characteristics than conventional novolaks because of the enhanced molecular weight and the inclusion of condensed hydrocarbon groups. The novel compound of this invention may have, for example, twice the molecular weight of the initial novolak resin.

I claim:

1. A naphthalene modified novolak resin having the structure:

OH OH -CH2 on,--omm where 12:1 to 8.

5 6 2. A naphthalene modified novolak resin having the structure:

OE OH OH OH OH 0H 05:

CH2 CH: CH OH OH: I

where n=1 to 8.

3. The method of making a naphthalene modified novolak resin having methylene linkages between naph- References Cited by the Examiner UNITED STATES PATENTS 1,102,634 7/1914 A lsworth 260-312 thalene and phenol groups and having substannally no 2,025,951 12/1935 Kzllzmick 1O6 22 ether linkages between naphthalene and phenol groups 15 2,330,827 10/1943 Kester 260 43 which comprises reacting a novolak resin with a chloro- 2,954,360 9/1960 Krzikalla et a1. 260-43 methyl naphthalene selected from the group consisting of l-chloromethyl naphthalene and di-(w-chIommethyD- naphthalene at an elevated temperature in the presence 20 of a Friedel-Crafts catalyst.

SAMUEL H. BLECH, Primary Examiner.

WILLIAM H. SHORT, Examiner.

H. SCHAIN, Assistant Examiner. 

1. A NAPHTHALENE MODIFIED NOVOLK RESIN HAVING THE STRUCTURE: 